Ultrasonic Transducer Cartridge

The subject disclosure relates ultrasonic flow meters for detecting the flow rate of a fluid, and more particular to fittings for housing a transducer for ultrasonic flow meters.

Ultrasonic flow meters have become integral in measuring the flow velocity or flow rate of liquids within conduits. Typically, paired transducers are strategically placed on the upstream and downstream sides of a conduit, for example as shown and described in U.S. Pat. No. 9,297,680 B2, filed Apr. 30, 2014, entitled ULTRASONIC FLOW METER HAVING DETERIORATION SUPPRESSION IN FLOW RATE ACCURACY, which is incorporated herein by reference. The emitted ultrasonic waves travel through the liquid, reflecting off the inner wall surface of the conduit, and are then captured by the opposing transducer. The time disparity in receiving these ultrasonic signals enables precise calculation of the liquid's flow characteristics.

Current ultrasonic flow sensor design has encountered a persistent challenge when attempting to position sensors centered within the flow path of a straight pipe. Existing designs often struggle to arrange transducers effectively while maintaining optimal signal transmission and reception.

Further, conventional sensor arrangements frequently involve holders or fixtures that may compromise the integrity of the conduit. The presence of mounting elements within the flow path adversely affects the accuracy of flow measurements and potentially causes damage to the system. Leakage concerns are particularly pronounced when attempting to integrate sensors within a straight pipe configuration. Existing designs may inadvertently compromise the structural integrity of the conduit or introduce weak points where leaks can occur. The challenge lies in finding a balance between securing the transducers in a manner that ensures accurate flow measurements and avoiding any compromise to the conduit's sealing properties.

In view of the above, a need exists for an ultrasonic transducer assembly that can be quickly and easily assembled while providing reliable operation. The improved assembly properly positions the sensor heads in the desired locations while keeping other components dry.

The present disclosure is directed to a sensor cartridge assembly for coupling in a fluid network. The cartridge assembly has a tubular body including a spoke extending radially inward and distally out of the tubular body. The spoke forms a hollow end and a conduit extending from an intermediate point of the tubular body into the hollow end. A sensor assembly includes a sensor head and a sensor lead extending from the sensor head through the conduit. A retaining nut couples to the hollow end to form a chamber, wherein the sensor head is retained in the chamber so that the conduit and, thereby the sensor lead, are sealed from fluid in the fluid network.

The tubular body may include a proximal flange extending radially outward to assemble with the fluid network to prevent fluid flow into the conduit. In one embodiment, the sensor cartridge assembly further comprises a first O-ring compressed by the retaining nut for preventing fluid passing by the sensor head into the conduit and maintaining a dry environment in the chamber and a second O-ring settled in an annular groove on the tubular body to prevent fluid travel over into the conduit. Preferably, the tubular body includes at least one additional spoke extending radially inward and distally out of the tubular body to support the hollow end.

The subject technology is also directed to an ultrasonic transducer cartridge for measuring the flow rate of fluid including a tubular body that defines first and second openings. The tubular body also defines an interior forming a fluid passageway along a flow axis between the first and second opening. The tubular body has an encasing spoke extending radially inward and distally out of the tubular body. The encasing spoke defines a conduit. A sensor assembly includes a flow sensor with a cable for electrical communication. The sensor assembly is propped in the flow axis of the ultrasonic transducer from the tubular body by the encasing spoke, wherein the conduit of encasing spoke is configured for guiding the cable of the flow sensor from the sensor assembly to an external portion of the ultrasonic transducer without exposure to the fluid.

In one embodiment, the ultrasonic transducer cartridge has support spokes extending radially inward and distally out of the tubular body with the encasing spoke, the support spokes also maintaining a position of the sensor assembly. The tubular body can include a proximal flange extending radially outward and perpendicular from the tubular body. Preferably, the transducer cartridge has two tail pieces, an ultrasonic transducer body disposed between the two tail pieces, and a union nut having proximal threading and a lip. The proximal threading is configured for sealingly capturing the proximal flange between the ultrasonic transducer body, one of the two tail pieces and the lip. The sensor cartridge assembly may also have one or more pressure sensor and temperature sensors mounted in the ultrasonic transducer body partially within the fluid passageway. Two O-rings can be provided, one of which prevents fluid contacting the flow sensor to proliferate into the conduit, and the other O-ring settled in an annular groove on the tubular body to prevent fluid travel over the tubular body of the ultrasonic transducer cartridge.

The subject technology is also directed to an ultrasonic transducer assembly for measuring the flow rate of fluid including a housing forming a fluid passageway along a flow axis between a first and second opening. The housing has a main body through which the fluid passageway extends and a tail piece abutting the main body, wherein the fluid passageway also extends through the tail piece. A tubular cartridge mounts in the housing, the cartridge defining an interior shaped to enable fluid ingress and egress therethrough. The cartridge further defines a proximal flange wedged sealingly between the tail piece and the main body. A union nut joins the main body and the tail piece together for holding the tubular cartridge in place.

In one embodiment, the tubular cartridge has an encasing spoke extending radially inward and distally out of the tubular cartridge from an intermediate opening in the tubular cartridge to a hollow end, the encasing spoke defining a conduit from the intermediate opening to the hollow end. The tubular cartridge also includes a sensor assembly with a sensor head and a sensor lead connected to the sensor assembly, wherein the sensor head is mounted in the hollow end and the sensor lead extends from the sensor head through the conduit. The sensor cartridge assembly may include a first O-ring in the hollow end for prevent fluid contacting the sensor head and proliferating into the conduit of the encasing spoke and a second other O-ring settled in an annular groove in the tubular cartridge to prevent fluid travelling over the tubular cartridge, and as such, a dry chamber is formed around the tubular body in communication with the conduit, wherein the main body defines a feeder hole in communication with the dry chamber and the sensor lead passes through the feeder hole.

The sensor cartridge assembly can also be provided so that the housing has a second tail piece opposing the tail piece and abutting the main body with the fluid passageway also extending through the second tail piece. A second tubular cartridge mounts in the housing, the second tubular cartridge defining an interior shaped to enable fluid ingress and egress therethrough, the second tubular cartridge further defining a proximal flange wedged sealingly between the second tail piece and the main body. A second union nut joins the main body and the second tail piece together for fixing the second tubular cartridge in place so that a predetermined distance between the sensor assemblies is set.

The subject technology overcomes many of the prior art problems associated with ultrasonic transducers assemblies. The advantages, and other features of the technology disclosed herein, will become more readily apparent to those having ordinary skill in the art from the following detailed description of certain exemplary embodiments taken in combination with the drawings and wherein like reference numerals identify similar structural elements. It should be noted that directional indications such as vertical, horizontal, upward, downward, right, left and the like, are used with respect to the figures and not meant in a limiting manner.

1 2 FIGS.and 100 Referring now to, perspective and end views of an ultrasonic flow meter assemblyare shown. Generally, ultrasonic flow meter assemblies have paired transducers or sensors that are arranged respectively on an upstream side and a downstream side of a conduit through which a liquid flows. Ultrasonic waves transmitted from one of the transducers or sensors are received by the other of the transducers, and a flow velocity or a flow rate of the liquid is measured based on a difference in propagation velocities of the ultrasonic waves. As such, a distance between the sensors is typically predetermined to produce accurate readings and preferably held steady.

100 101 102 104 104 104 106 104 106 106 106 106 106 102 104 104 a b a a b b a b a b a b The ultrasonic flow meter assemblyof the present application has housingincluding a main bodyinterposed between two tail pieces,. A first tail piece, defines an inletfor connecting to a fluid network (not shown) and alternatively serving as an outlet. The second tail piece, defines an outletalso for connecting to the fluid network and alternatively functioning as an inlet. As shown, the inletand the outletare simply threaded to engage a traditional fitting. The terms inlet and outlet may be referred to herein simply as an opening due to the interchangeability thereof. It is envisioned that the inletand the outlet, could be adapted (e.g., coupled to a nipple), reconfigured (e.g., changed from male to female and vice versa), and rearranged (e.g., oriented at an angle such as 90 degrees) for inclusion in any desired network. Together, the main bodyand two tail pieces,form a conduit shape with cylindrical contour.

102 103 105 103 102 140 142 102 138 138 102 131 105 104 105 112 The main bodyhas a central narrower portionwith relatively larger end portions. The central narrower portionof the main bodydefines orificesthat receive demountable couplingsfor sampling of the fluid in the main bodyby probes. Each probemay sense pressure, temperature or both. The main bodyalso defines two spaced apart feeder holesin the relatively larger end portions. Each tailpieceis coupled to the respective larger end portionby a union nut.

3 4 4 FIGS.,andA 100 100 110 106 106 102 108 110 105 109 134 a b Referring now tocross-sectional views of the ultrasonic flow meter assemblyare shown. The ultrasonic flow meter assemblydefines a fluid passagewayalong a flow axis “a” between the inletand the outlet. The main bodydefines an interiorthat is part of the fluid passageway. The larger portionshave a necked down seal pointand terminate with an inner rim.

104 104 126 130 117 130 112 115 120 120 122 134 117 122 200 200 110 102 200 200 104 104 112 a b a b a b a b Each tailpiece,has an exterior threaded portionthat abuts a pedestal portion. An end flangeextends outward from the pedestal portion. Each union nuthas a threaded endextending from a shoulder. The shoulderhas an inner lip. The inner rim, the outer end flangeand the inner lipare all approximately the same size. Two cartridges,are disposed in the fluid passagewayalong the flow axis “a”, which will be described below. The main body, cartridges,, and tail pieces,are joined by the union nutdisposed therearound.

5 7 FIGS.- 200 200 202 204 110 200 206 208 202 Referring to, perspective views of an isolated cartridgeare shown. The cartridge assemblyhas a tubular bodythat is cylindrical in contour, complimentary to the interior of a traditional conduit and defines an internal cavitythat forms part of the fluid passageway. The cartridge assemblyalso defines a flangeextending radially outward and perpendicular from a first endof the tubular body.

200 210 210 212 252 212 210 110 204 200 216 218 218 204 a b The cartridge assemblyalso has a sensor assembly. The sensor assemblyincludes a flow sensor headand an electrical cableextending from the sensor head. The sensor assemblyis centered in passagewayand propped from the internal cavityof the cartridge assemblyby at least one encasing spokeand support spokes,, extending out of the cavity.

216 218 218 204 204 200 214 200 208 216 218 218 227 210 219 216 218 227 a b a b 2 FIG. 2 FIG. The encasing spokeand two support spokes,are disposed relatively equidistant from one another circumferentially within the internal cavity(see), and extend from the internal cavityof the cartridge assemblyin a central direction towards the second endof the cartridge assembly, opposite from the first end. The encasing spokeand two support spokes,coalesce in a hollow endthat houses the sensor assemblysituated along the flow axis “a”. As best seen in, three arcuate slotsare formed between the spokes,to allow flow around the hollow end.

216 220 220 222 202 100 224 227 216 210 220 110 7 FIG. The encasing spoke, as is particularly highlighted in, forms an internal conduit. The internal conduitpropagates from an intermediate opening pointof the tubular bodyof the ultrasonic transducer cartridge, to a chamberpartially formed by the hollow end. The encasing spokeand the sensor assemblymay be integrally formed, but are not shown as such. When integrally formed, sealing the conduitfrom the fluid passagewayis structurally simpler.

7 FIG. 216 204 200 220 227 224 227 216 228 230 230 232 In the embodiment shown in, the encasing spokepropagates relatively linearly from the internal cavityof the cartridge assembly. The internal conduitthereafter transitions into the hollow endthat forms part of the chamber. The hollow endof the encasing spokeforms a shoulderfollowed by a threaded end. The threaded endterminates in a distal end.

238 230 224 238 240 212 212 110 252 212 220 131 102 A retaining nutcouples to the threaded endhelping to form the chamber. The retaining nutdefines an openingto chamber. As a result, when the flow sensor headis fixed in the chamber, a portion of the sensor headis exposed to the fluid passageway. The electrical cableextends from the sensor headthrough the conduitand out of the respective feeder holein the main body.

238 242 240 212 224 232 236 238 230 212 244 246 212 224 220 250 212 238 The retaining nuthas a radially inward rimsurrounding the openingfor fixing the sensor headin the chamberagainst the distal endwhen a threaded endof the retaining nutcouples to the other threaded end. Preferably, the sensor headincludes an annulusthat carries an O-ringto prevent fluid from passing by the sensor headand further into the chamberand conduit. Preferably, a dry sideof the sensorsnuggly fits in the retaining nut.

202 200 256 258 256 109 102 200 110 219 216 218 The tubular bodyof the cartridgeincludes an O-ringset in a grooveso that the O-ringis compressed against the sealing pointof the main bodyto prevent fluid from passing around the cartridge. As a result, the flow of the fluid passagewaygoes through the arcuate slotsformed between the spokes,.

4 FIG.A 257 202 104 206 202 200 257 117 257 221 202 109 117 206 131 220 221 Referring to, at least one O-ringis also compressed between the tubular bodyand the tailpiece. More particularly, the flangeof the tubular bodyof the cartridgecompresses two O-ringsagainst the flangeof the tailpiece. As such, a dry chamberis formed around the tubular bodybetween the sealing pointand the flanges,. The feeder holesand the conduitare connected to the dry chamber.

224 220 221 252 212 100 218 218 210 204 200 a b In this configuration, the chamber, internal conduitand dry chamberremain dry, enabling the electrical cableof the sensorto reach an external connection of the ultrasonic transducer assembly. If further cabling is necessary, embodiments may include several encasing spokes or several cables within a single spoke. The support spokes,, in the alternative, do not have an internal conduit and serve to prop the sensor assemblyfrom the support of the internal cavityof the cartridge assembly. With that said, one having ordinary skill in the art will appreciate that the cartridge may have several or no encasing spokes, and similarly, several or no support spokes.

3 7 FIGS.- 100 200 212 234 210 252 220 216 200 246 244 212 238 230 210 236 238 212 246 Referring to, to construct the ultrasonic transducer assembly, each cartridgeis pre-assembled by placing the sensorin the sensor fittingof the sensor assemblyand the respective cableis fed through the internal conduitof the encasing spokeof the cartridge assembly. The O-ringis set in the annulusof the sensor head. The retaining nutis subsequently rotated to tighten the threaded endof the sensor assemblywith the threadsof the retaining nut, snugly capturing the sensorand sealing by compression of the O-ring.

200 102 212 210 252 144 102 200 206 134 102 200 212 212 212 Each cartridge assemblyis then inserted into the main body, with the sensor headof the sensor assemblyinserted first/facing inward. The cablecan further be fed through a cable emission intermediate pointin the main body. The cartridge assemblyis nearly fully inserted before the flangeabuts the inner rimof the main body. Thus, axial location of each cartridge assemblyis predetermined and fixed with the sensor headsfacing each other. By setting the location of the sensor heads, a distance d between the sensor headsis set for proper operation.

112 102 122 104 117 257 206 202 134 102 122 122 112 130 104 138 138 110 140 142 4 FIG.A The union nutsthread on to the main bodyforcing the inner lipsof the tailpiecesinward so that the flangeof the tailpieces, the at least one O-ring, and flangeof the cartridge tubular bodyare compressed together between the inner rimof the main bodyand the inner lips(see). The lipsof the union nutsrest on a pedestal portionof the tailpiecesto facilitate assembly. As preferred, a pressure sensor probeand/or temperature sensorare inserted partially within the fluid passagewaythrough the one or more orificesand demountable couplings.

3 FIG. 110 212 200 111 102 212 200 a a b b. In operation, as best shown in, when liquid flows inside the fluid passageway, acoustic wave signals are transmitted, for example, from the first sensor headsituated in the first cartridge assembly. The acoustic wave signals propagate inside the liquid while being reflected by the interior surfaceof the main body, and are received by the second sensor headsituated in the second cartridge assembly

212 200 111 102 212 200 b b a a. In a reverse scenario, acoustic wave signals are transmitted from the second detection sensor headsituated in the second cartridge assembly. The acoustic wave signals propagate inside the liquid while being reflected by the interior surfaceof the main body, and are received by the first detection sensorsituated in the first cartridge assembly

212 212 252 252 a b a b In addition, reception signals based on the acoustic wave signals, which are received by the detection sensor heads,, are output to a controller (not distinctly shown) through the cables,. A propagation time difference AT is calculated from the detection signals by the controller, not shown, based on a propagation time of the first versus second scenario. A velocity V, i.e., a flow rate, of the liquid is calculated from the propagation time difference AT.

8 9 FIGS.and 1000 100 1000 1000 1216 1200 1202 1206 1208 1202 1200 1210 1212 1214 1202 Referring now to, another embodiment of an ultrasonic transducer cartridge assemblyis shown. Like numerals will be used to describe like elements of theseries labeling as in theseries labeling. The ultrasonic transducer cartridge assemblyuses a single encasing spokeand no support spokes. The cartridge, as with the previously explained embodiment, has an exteriorthat is substantially cylindrical in contour, complimentary to the interior of a traditional conduit. Along with the proximal flangeprolonging radially outward and perpendicular from the first endof the cylindrical exterior, the cartridgestill has a sensor assemblyconfigured for containment of a flow sensor headdisposed proximate to the second endof the cylindrical exterior.

1210 1216 1204 1200 1260 1262 1202 1206 1216 1214 1208 1206 1204 1260 1210 1110 1210 1202 9 FIG. Differing in this embodiment, the sensor assemblyis propped, via the single encasing spoke, from the internal cavityof the cartridgeand additionally supported by a banddisposed on an edgeof the cylindrical body, opposite the proximal flange. The encasing spokeprolongs in the direction of the second end, opposite from the first endand proximal flange, and is angled from the internal cavityand bandto situate the sensor assemblyalong the flow axis “a”. As best seen in, the fluid passagewayflows around the sensor assemblyand through the tubular body.

1216 1260 1200 1216 1264 1260 1220 1222 1252 1131 1000 1252 1212 1000 Because the encasing spokedepends from the bandof the cartridge, the encasing spokedivides partially at a convergence pointto affix to the bandwhile still providing a conduitin fluid communication from an intermediate pointof egress to pass the cablethrough the feeder holeof the ultrasonic transducer cartridge assembly. In this configuration, the chamber and conduit again remain dry enabling the cableof the sensorto reach an external of the ultrasonic transducer cartridgewithout fluid intervention.

10 FIG. 1216 1212 1266 1266 1267 1269 Referring now to, the cabling (not distinctly shown) propagates through the conduit of the encasing spokefrom the sensor head, and terminates as an electrical screw connector. The connectormay align with the feeder hole of the main body so that wires can simply be inserted into the capture holeand set in place by the associate screwto make the necessary electrical connections.

11 FIG. 1212 1266 1268 1268 1268 Referring now to, the cabling (not distinctly shown) from the sensor headterminates as an electrical socket connector. As such, once the external connectoris fed through, the connectormay be quickly and easily inserted into the socket connectorto make the electrical connection. In another embodiment, the sensor assembly operates wirelessly

It will be appreciated by those of ordinary skill in the pertinent art that the functions of several elements can, in alternative embodiments, be carried out by fewer elements, or a single element. Similarly, in some embodiments, any functional element can perform fewer, or different, operations than those described with respect to the illustrated embodiment. Also, functional elements (e.g., check valves, valve elements, spring retention assemblies, and the like) shown as distinct for purposes of illustration can be incorporated within other functional elements in a particular embodiment.

While the subject technology has been described with respect to various embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the subject technology without departing from the scope of the present disclosure.